Grouped screw bunch and related method and machine for production of the same

ABSTRACT

A screw bunch includes a plurality of screws grouped together in a bunch with the enlarged head end of each screw toward a first end of the bunch and the pointed tip end of each screw toward a second end of the bunch. The screws are held together in the bunch by a band structure that extends around the bunch and that engages with the shanks of a multiplicity of the screws that are located along a perimeter of the bunch. The enlarged head ends of the screws are axially staggered. The band structure may be formed by a shrink wrap plastic band that can be separated from the bunch manually to enable individual retrieval of screws from the bunch for use. A method and machinery for production of the screw bunch is also provided.

TECHNICAL FIELD

This application relates generally to screws utilized by builders forgeneral construction and, more specifically, to a grouped screw bunchthat facilitates handling and use of the screws.

BACKGROUND

Builders commonly use bulk screws for various projects. The contractorstypically fill a work-belt pouch with screws from a bulk screw source(e.g., a bucket or bin) and then occasionally grab hand-size bunches ofscrews from the pouch when working. The problem with this system is thatthe bulk screws in the pouch tend to become oriented in multipledirections and it is difficult to remove a hand-size bunch of screwsfrom the pouch without dropping some or without at least taking time toorient all of the screws in the same direction, which reducesproductivity and is also frustrating for the worker.

It would be desirable to provide a solution that addresses the aboveissue(s).

SUMMARY

In one aspect, a screw bunch includes a plurality of screws, each screwhaving an enlarged head end, a pointed tip end and shank extendingbetween the enlarged head end and the pointed tip end, the shank beingat least partially threaded. The plurality of screws are groupedtogether in a bunch with the enlarged head end of each screw toward afirst end of the bunch and the pointed tip end of each screw toward asecond end of the bunch. The plurality of screws are held together inthe bunch by a band structure that extends around the bunch and thatengages with the shanks of a multiplicity of the screws that are locatedalong a perimeter of the bunch. The enlarged head ends of the pluralityof the screws are axially staggered, such that a head end perimeterdimension of the bunch is smaller than would be the case if the headends were not axially staggered. The band structure comprises a shrinkwrap plastic band that can be separated from the bunch manually toenable individual retrieval of screws from the bunch for use.

In another aspect, a screw bunch includes a plurality of screws, eachscrew having an enlarged head end, a pointed tip end and shank extendingbetween the enlarged head end and the pointed tip end, the shank beingat least partially threaded. The plurality of screws are groupedtogether in a bunch having an elongated axis, wherein the enlarged headend of each screw toward a first end of the bunch and the pointed tipend of each screw toward a second end of the bunch. The plurality ofscrews are held together in the bunch by a band structure that extendsaround the bunch and that engages with the shanks of a multiplicity ofthe screws that are located along a perimeter of the bunch. The enlargedhead ends of the plurality of screws are axially staggered, such thatthe enlarged head ends of multiple screws overlap in an end view alongthe elongated axis and such that a head end perimeter dimension of thebunch is smaller than would be the case if the head ends were notaxially staggered.

In a further aspect, a method of producing a screw bunch involves:positioning a plurality of screws in a set with head ends of the screwscommonly oriented toward one axial end of the set and with the head endshaving axially staggered positions relative to each other; positioning aband member about the set of screws; and tightening the band memberabout the set of screws causing the set to collapse inwardly toward acentral axis of the set.

In yet another aspect, a method of producing a screw bunch involves:separating a plurality of screws into a plurality of screw sets, eachscrew set including a common number of screws; dropping one screw setinto a tubular member; applying a shrink sleeve member around thetubular member; moving the tubular member to a raised position to exposethe one screw set, such that the tubular member is no longer positionedbetween the shrink sleeve member and the one screw set, wherein, in thefirst raised position, the tubular member surrounds an upper end of theone screw set; applying heat to the shrink sleeve member while thetubular member is in the raised position, causing the shrink sleevemember to shrink into holding contact with the one screw set to form awrapped screw bunch; cooling the shrink sleeve member; and moving thetubular member to a further raised position that is higher than thefirst raised position, such that the wrapped screw bunch is no longersurrounded by the tubular member and can be removed from the loadingstation.

In still another aspect, a machine for producing wrapped screw bunchesincludes a turntable including a plurality of screw load stations, theturntable rotatable about a first rotation axis, each screw load stationincluding an associated tubular member and an associated tube lifter. Acarousel includes a plurality of downwardly sloped screw channels forsupporting groups of screws, the carousel rotatable about a secondrotation axis, the carousel surrounded by a stationary wall having anoutlet gate that is selectively alignable with an outfeed end of eachscrew channel based upon rotational position of the carousel. A curvedfeed track running downwardly from the outlet gate such that screws canslide downward along the feed track, the feed track having an outletend. A drop funnel has a support track with an inlet end that is alignedwith the outlet end of the feed track, the support track formed in partby a wall of the drop funnel and in part by a movable gate of the dropfunnel, the drop funnel including a bottom opening. Each screw loadstation is rotatable along a path that includes a position below thebottom opening so that a group of screws can be dropped into the tubularmember of the load station to form a loaded tube.

The details of one or more embodiments are set forth in the accompanyingdrawings and the description below. Other features, objects, andadvantages will be apparent from the description and drawings, and fromthe claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1F show images for one embodiment of a wrapped screw bunch;

FIGS. 2A-2E show images of another embodiment of a wrapped screw bunch;

FIGS. 2F and 2G show images of another embodiment of a wrapped screwbunch;

FIGS. 3A-3B show a package assembly of multiple wrapped screw bunches;

FIGS. 4A-4I shows a sequence of forming a wrapped screw bunch;

FIGS. 5A-5B depict heating/cooling sequences;

FIG. 5C shows an exemplary temperature variation;

FIG. 6 shows one embodiment of a system for producing wrapped screwbunches;

FIGS. 7 and 8 show partial perspectives of a turntable and tube liftassembly;

FIGS. 9 and 10 show perspectives of a tube lift assembly;

FIG. 11 shows a tubular member;

FIGS. 12-16 depict a rotation sequence of the turntable to produce awrapped screw bunch;

FIGS. 17 and 18 show partial perspectives of the system;

FIG. 19 shows a perspective of a carousel;

FIG. 20 depicts the spiral feed of screws to a drop funnel;

FIG. 21 depicts a section view of a drop funnel holding a screw set;

FIGS. 22A-22D show a screw drop sequence; and

FIGS. 23A-23B show another drop funnel embodiment.

DETAILED DESCRIPTION

Referring to FIGS. 1A-1E, one embodiment of a wrapped screw bunch 10 isshown. The screw bunch is formed by a plurality of screws 12, where eachscrew has an enlarged head end 14, a pointed tip end 16 and a shank 18extending between the enlarged head end and the pointed tip end, withthe shank being at least partially threaded. The plurality screws aregrouped together in a handhold sized bunch, with the enlarged head endof each screw toward a first end 20 of the bunch and the pointed tip endof each screw toward a second end 22 of the bunch. By way of example, atypical bunch may be formed by between ten and fifteen screws, thoughthe number can vary based upon factors such as screw type and screwsize.

As shown, the enlarged head ends 14 of the screws 12 are axiallystaggered (e.g., the axial position of the head ends 14 relative to anoverall central axis 26 of the screw bunch varies). This axialstaggering of the head ends 14 results in a configuration in which ahead end perimeter dimension of the bunch is smaller than would be thecase if the head ends were not axially staggered. In particular, aprojected circular perimeter dimension of the head end of the staggeredbunch 10 from a view looking along the axis 26, which is represented bya dashed line 28 in FIG. 1E, is smaller than the comparable circularperimeter dimension for a non-staggered bunch having the same number ofscrews, which is represented by a dashed line 30 in FIG. 1F. Inaddition, as also shown in FIG. 1E, the enlarged head ends of multiplescrews overlap in an end view along the elongated axis. Typically,groups of three or more (e.g., four or more) screws will have head endsthat overlap in the end view.

The screws are held together in the bunch by a band structure 24 thatextends around the bunch and engages with the shanks of the screws thatare located along a perimeter of the bunch (e.g., any screws that areonly in the center of the bunch would not be engaged directly by theband structure). Here, the band structure 24 is formed by a shrink wrapplastic band that can be separated from the bunch manually to enableindividual retrieval of screws 12 from the bunch for use. However, inother embodiments, different band structures may be used, such aselastic bands, adhesive bands, biodegradable bands or bands of the twisttie or zip tie type. FIGS. 1B-1C depict exemplary band separation wherethe shrink wrap plastic band includes a tear wrap tab 32 extending fromthe screw bunch such that the tear wrap tab 32 can be manually grippedfor tearing the shrink wrap plastic band away from the screw bunch asshown. The tab 32 may be formed by a sheet member 34 that around which aportion of the shrink wrap plastic is shrunk to retain the sheet member.By way of example, the sheet member 34 may be a cardboard panel or aplastic panel. Notably, the shrink wrap plastic band may also includeone or more perforation lines to help facilitate band separation.

FIGS. 2A-2E depict another example of a wrapped screw bunch 40 withmultiple screws 42 in a shrink wrap plastic band 44 that lacks any teartab. In this case, the band 44 includes perforations 46 that create oneor more separation lines to aid in separation of the band by pullinglaterally on the end of one of the screws 42 to apply sufficient forceto the band 44, causing it to split along the separation line as shown.

FIGS. 2F and 2G depict another example of a wrapped screw bunch 340 withmultiple screws 342 in a shrink wrap plastic band 344 that lacks anytear tab. Here the band 344 includes multiple separation zones 350, eachof which runs from top to bottom of the band. Each separation zone 350is made up of a series of lateral perforations 352 (elongated slotperforations) spaced apart (e.g., equally) along the height of the band344 and thus spaced apart along a lengthwise axis 326 of the screwbunch. The separation zones 350 are also spaced apart (e.g., equally)around the perimeter of the band 344 (e.g., the full perimeter). Thelateral slot perforations have been found to provide adequate resistanceagainst inadvertent splitting of the band (e.g., splitting of the bandwhen the screw bunch is in transport or if the screw bunch is dropped)while still allowing splitting under used circumstances in which aperson grips one of the screws and pulls it against the band. Theinclusion of multiple separation zones around the periphery of the band344 is advantageous in assuring that a person can separate the band bypulling a screw against the band in any position (e.g., regardless ofthe rotational position of the screw bunch within the person's hand). Inthis regard, it is generally desirable to include at least six distinctseparation zones around the periphery of the band, such as at leasteight distinct separation zones or at least ten distinct separationzones.

In the case of bunch 10 or bunch 40 or bunch 340, the shrink wrapmaterial can be shrunk enough to assure that some of the plastic filmmaterial moves down into the spaces between threads on the shanks of theperimeter screws, which assures that the band will not simply fall offof the bunch. In addition, contact between the respective threads of thescrews in the bunch, caused by the screws being squeezed together by theshrink wrap plastic band, helps to prevent relative axial sliding of thescrews, which prevents the screws from simply falling out of the bunch.

In the illustrated embodiments, the band structures 24, 44, 344 arelocated along a region of the screws that is spaced from both thepointed ends of the screws and the enlarged head ends of the screws. Insome implementations, this configuration will result in a bundle inwhich a smallest perimeter dimension of the bundles is along an axialregion that is aligned with part of the band structure.

FIGS. 3A and 3B depict an exemplary screw package assembly 50 formed bya container 52 in which a plurality of screw bunches 10 are placed. Theillustrated container 52 is in the form of a rectangular tub, box orbucket (e.g., a tub body 54 with a removable lid 56).

Using exemplary screw bundles packaged as shown, a typical worker wouldremove a number of the wrapped bunches from the tub, place those bunchesin the pouch of work belt, remove one or more bunches from the pouch,remove the wrap from at least one bunch and selectively pull each screwfrom the bundle for install. This process or sequence assures that allscrews will be immediately oriented properly in the workers hand withoutany fumbling or dropping of screws.

Referring now to FIGS. 4A-4I, a schematic diagram sequencing productionof a wrapped screw bunch is shown, and contemplates use of a loadingstation 60 that includes a support frame 62 with a top opening 64 and ascrew support hub 66 that aligns with the top opening and positionedwithin the frame interior. The loading station also includes a tubularmember 68 that is movable between a lowered position seated down intothe support frame 62 and disposed around the screw support hub, andmultiple raised positions in which the tubular member is spaced abovethe support frame 62. To produce a wrapped screw bunch, a plurality ofscrews 12 are separated into a plurality of screw sets or groups 70(only one set shown), where each screw set or group includes a commonnumber of screws (e.g., 12 or 15 or other number). The loading station60, with tubular member 68 in its lowered position, is positioned inalignment with a drop path 72 of the screw set per FIG. 4A, and thescrew set is then dropped into the tubular member per FIG. 4B. Notably,the upwardly facing support surface of the screw support hub 66 isnon-planar, which helps to create the above mentioned axial staggeringof the screw heads. In the illustrated embodiment, the support surfaceis conical, but other variations are possible. In addition, the lowerend of the tubular member 68 surrounds and cooperates with the upwardlyprojection portion of the screw support hub 66 and/or cooperates withthe opening 64 in the support frame to help maintain the tubular memberin an axially upright position.

The loading station 60 is positioned such that a feed path 74 of ashrink wrap plastic band 76, also commonly referred to a shrink sleeveband, will cause the plastic band to be applied around the tubularmember, resulting in the configuration of FIG. 4C. The tubular member 68can then be lifted a first raised position (per FIG. 4D) to expose thescrew set 70, such that the tubular member 68 is no longer positionedbetween the shrink sleeve band 76 and the screw set. In this position,the lower end of the tubular member 68 still surrounds an upper end ofthe screw set in order to maintain the upright orientation of the screwset. Heat 78 is then applied to the shrink sleeve band 76 while thetubular member is raised (e.g., by moving the loading station through aheat shrink tunnel with heating elements), causing the shrink sleeve toshrink into holding contact with the screw set to form a wrapped screwbunch. The tubular member is then lifted to a second raised position(per FIG. 4E) and cooling air 80 is applied the shrink sleeve member(e.g., by moving the loading station 60 to a location at which coolingair is fed into the frame 62 and flows upward and out of top openings inthe frame 62). The further raised position of the tubular member helpsto enhance the cooling, while at the same time the lower end of thetubular member still surrounds the upper end of the screw set tomaintain the upright orientation of the screw set. After cooling, thetubular member 68 is lifted further to a position separated from thescrew set (per FIG. 4F) so that the wrapped screw bunch can be placedonto a conveyor 82 to move the wrapped screw bunch to a location forfurther heating 84 (per FIG. 4G, e.g., by passing through anotherheating tunnel) and further cooling 86 (per FIG. 4H, e.g., by passing byanother cooling air station). The wrapped screw bunch can then beconveyed and dropped into a box, tub or bucket for packaging.

Use of the secondary heating operation has been found to provide a moretightly wrapped screw bunch, which helps assure the screws remain in thewrapped bunch during shipping. FIG. 5A schematically depicts animplementation in which the first or primary heating step 90 and thesecondary heating step 92 take place in distinct locations (e.g.,different heating tunnels 90-1 and 92-1 separated by a cooling station94). FIG. 5B schematically depicts an implementation in which theprimary heating step 90 and the secondary heating step 92 take place ina common heating tunnel 90-3 that also includes cooling zones 96, 98therein. In the latter regard, FIG. 5C reflects that various heatingprofiles could be applied as desired. Other variations are possible.

Referring now to FIG. 6, one embodiment of a system 100 for producingwrapped screw bunches is partially shown. The system 100 includes arotatable station turntable 102 that includes a plurality of loadingstations, one or more rotatable carousels 104 that feed screwgroups/sets to respective drop funnels 105, a shrink sleeve applyingmachine 106 for applying the shrink sleeve bands, a heating tunnel 108for applying heat to the banded screw sets and a cooling air flow duct110.

As seen in FIGS. 7-11, the turntable 102 includes a plurality of loadingstations 120, each of which has an associated pair of parallel throughslots 122. Here, only one loading station includes a support frame 124and associated tubular member 126, but it is recognized that some (e.g.,every other) or all of the other stations would also include thosecomponents. The turntable 102 is ring-shaped and disposed around astationary cam plate 130 that defines a recessed cam slot 132. Theloading station includes a tube lift assembly 134 that includes a guidearm 136 with an inner end 138 carrying a cam wheel roller 140 that ridesin the cam slot 132, an upper lift bracket 142 that can engage andsupport the tubular member 126 and a lower portion 146 below theturntable 102. The lift bracket 142 is connected to spaced apartrods/bars 144 that extend down through the slots and that can move bothup and down through the slots (within respective bushings 145) and alongthe length of the slots. The interaction of the cam roller 140 and thecam slot 132 causes the movement along the length of the slots. As seenin FIG. 9, the lower portion 146 includes a supporting roller wheel 148that can ride on a surface below the turntable 102 to cause the upwardand downward movement of the rods 144 and lift bracket 142. In theillustrated embodiment, the lift bracket 142 is U-shaped, with spacedapart arms 150 that define a slot 153 to receive the tubular member, andthe bracket also defines a shelf surface 152 that can engage with adownwardly facing rim 154 formed by a recessed external surface portion156 of the tubular member 124 in order to vertically support the tubularmember 124. The end portion of each arm 150 includes a grip member 158facing into the slot 153 so that the grip members 158 can contact thetubular member and provide a holding force to retain the tubular memberagainst falling away and out of the open end of the slot 153. In oneexample, the grip member 158 can be rubber plugs that extend partiallyinto the slot and frictionally engage the external surface of thetubular member, but other variations are possible.

Referring again to FIG. 8, a side opening 160 in the frame 124 providesan entry point for the cooling air, and the cooling air will exitupwardly through openings 162 in the upper surface of the frame 124 soas to be directed onto a wrapped screw bunch (not shown).

Referring now to FIGS. 12-16, a sequence of system operation, withrotation of the turntable 102 in the clockwise direction 170 is shown.In the position of FIG. 12, a tube lift assembly 134 of a loadingstation is upstream of a carousel 104. In FIG. 13, the tube liftassembly is rotated to a location beneath a drop funnel associated withthe first carousel 104 (so that the screws can be dropped into thetubular member). In the position of FIG. 14, the tube lift assembly isnow positioned below the sleeve applying machine 106, which includes anassociated drop point 107 for the tubular bands. Notably, the cam slot132 extends inward in this region of turntable rotation so that the tubelift assembly, including the lift bracket, will be pulled away from thetubular member of the load station so as to not interfere with theapplication of the shrink wrap band about the tubular member. As theturntable continues to rotate toward the heating tunnel 108, the camslot extends back outward so that the tube lift bracket will engage withthe tubular member to facilitate lifting of the tubular member as theloading station moves through the heating tunnel 108. FIG. 15 shows theturntable 102 rotated to a position in which the tube lift assembly 134aligns with the entry of the heating tunnel 108, and FIG. 16 shows aposition in which the turntable 102 is rotated to a position in whichthe tube lift assembly 134 is in the region of the cooling air flow duct110, which includes one or more radially inwardly facing slots to alignwith the loading station frame side opening 160 (FIG. 8) and deliver thecooling air for cooling.

As seen in FIG. 17, the turntable 102 is positioned above a stationaryplate 180. The lower roller 148 (FIG. 9) of the tube lift assemblynormally rides along the upper surface of the plate, and when in suchposition, the tubular member 126 will be in its lowered position (e.g.,comparable to 4A of FIG. 4). However, a rail structure 182 is located onthe plate 180 and is located with a ramp surface 184 that will interactwith the lower wheel 148, causing the lift bracket 142 is rise and liftthe tubular member into a raised position suitable to expose the screwsand shrink wrap band for heating (e.g., comparable to 4D) of FIG. 4).The rail structure 182 includes a further ramp surface 186 to cause thelift bracket to be further raised for the cooling operation (e.g., intoa position comparable to 4E of FIG. 4). As seen in FIG. 18, the railstructure 182 includes a further ramp surface 188 to cause the liftbracket 142 to further raise into a position that permits removal of thewrapped screw bunch (e.g., comparable to 4F of FIG. 4). A downwardramped surface 190 causes lowering of the lift bracket 142 andassociated tubular member in preparation for another sequence ofrotation.

Referring now to FIG. 19, a perspective view of one embodiment of acarousel 104 with an associated drop funnel 105 and a downwardlyspiraling screw feed track 210 is shown. The carousel includes aplurality of downwardly angled channels 212 formed by spaced apartplates 214, 216. The spacing between the plates is sufficient to allowthe shank of the screws to extend down into the channel, but to preventthe enlarged screw head from entering the channel. In operation, sets orgroups of screws are positioned within each channel 212, with the screwssupported by engagement of the lower surface of the screw heads with theupper edges of the plates. A stationary wall 218 is provided and has anoutlet gate 220 that will selectively align with each channel byrotational position of the carousel channels 212. When a given channel212 aligns with the gate 220, the screws in that channel slide down intothe feed track 210 and toward the drop funnel. The screws are supportedin the feed track 210 by the head ends, similarly as in the channels212, and FIG. 20 depicts the downwardly spiraling path of screws alongthe feed track 210 toward the drop funnel 105.

As seen in FIG. 21, the drop funnel 105 includes a support track 230with an inlet end 232 that is aligned with the outlet end of the feedtrack, and the support track 230 is formed in part by a wall of the dropfunnel and in part by a movable gate member 234 of the drop funnel. Thegate member 234 is linearly movable (e.g., by solenoid or pneumatics)from a hold or standby position to a drop position. In the hold orstandby position, the gate member 234 supports the screws by engagementwith the enlarged head ends of the screws (e.g., the screws hang in thesupport track as shown in FIG. 21). In the drop position, the gatemember 234 moves away from the enlarged head ends of the screws (e.g.,in direction 236) so that the screws are no longer supported and willdrop down the funnel as depicted in the sequence of FIGS. 22A-22D. Asthe screws drop, they move together into a tighter grouping. The dropfunnel 105 includes a bottom opening 238 that is sized to assure thatall dropped screws will properly enter the top opening of the tubularmember 126.

Referring to FIGS. 23A and 23B, a funnel embodiment includes a bottomportion 105A that can separate. Here, portion 105A may connect toportion 150B via a coupling 240. In one example, portion 105A ismagnetically retained to the coupling 240. If the screws become jammedand do not fully drop from the funnel when the tubular member shifts(e.g., in direction 242 here), the force exerted by screws on the funnelportion 105A will cause the funnel portion 105A to also shift andseparate, but without doing any permanent damage. A control of thesystem could detect the separation (e.g., using any suitable sensor) andshut down the operation of the system in such cases.

It is to be clearly understood that the above description is intended byway of illustration and example only, is not intended to be taken by wayof limitation, and that other changes and modifications are possible.For example, while the described embodiment of the machine contemplatesrollers and associated cam or ramp surfaces to achieve desired movementof the tube lift assembly, it is recognized that other variations arepossible, such as the use of actuators to control the up/down movementsand the in/out movements. Moreover, while the primary embodiment of theproduction process contemplates lifting the tubular member in order toprovide a suitable relative positioning between the shrink wrap plasticband and the screws for the purpose of heat shrink, other variations arepossible, such as lowering the support frame 124 rather than the tubularmember, which still creates the desired spaced position between thetubular member and the support frame, exposing the screw to the shrinkwrap band so that the band can shrink into contact with the screwswithout interference from the tubular member. Further, while the primaryembodiment of the machine contemplates a rotational production line, aproduction line with a linear configuration could also be implemented.Such a linear configuration would provide for additional manufacturingstation space, improved station volume flexibility and improvedproduction scalability.

Still other variations and modifications are possible.

What is claimed is: 1-16. (canceled)
 17. A method of producing a screwbunch, comprising: positioning a plurality of screws in a set with headends of the screws commonly oriented toward one axial end of the set andwith the head ends having axially staggered positions relative to eachother; positioning a band member about the set of screws; tightening theband member about the set of screws causing the set to collapse inwardlytoward a central axis of the set.
 18. The method of claim 17, including:separating a plurality of screws into a plurality of screw sets, eachscrew set including a common number of screws; dropping one screw setinto a tubular member; applying a shrink sleeve member around thetubular member; moving the tubular member to a raised position to exposethe one screw set, such that the tubular member is no longer positionedbetween the shrink sleeve member and the one screw set, wherein, in thefirst raised position, the tubular member surrounds an upper end of theone screw set; applying heat to the shrink sleeve member while thetubular member is in the raised position, causing the shrink sleevemember to shrink into holding contact with the one screw set to form awrapped screw bunch; cooling the shrink sleeve member; moving thetubular member to a further raised position that is higher than thefirst raised position, such that the wrapped screw bunch is no longersurrounded by the tubular member and can be removed.
 19. The method ofclaim 18 wherein the tubular member is moved to an intermediate raisedposition after applying the heat and before the cooling, where theintermediate raised position is higher than the raised position andlower than the further raised position.
 20. The method of claim 17including: positioning the plurality of screws of the set within atubular member; applying the band member, in the form of a shrink sleevemember, around the tubular member; moving the tubular member to a firstset position to expose the screws of the set, such that the tubularmember is no longer positioned between the shrink sleeve member and thescrews; applying heat to the shrink sleeve member while the tubularmember is not positioned between the shrink sleeve member and thescrews, causing the shrink sleeve member to shrink into holding contactwith the screws to collapse the screws and form a wrapped screw bunch;cooling the shrink sleeve member.
 21. A method of producing a screwbunch, comprising: separating a plurality of screws into a plurality ofscrew sets, each screw set including a common number of screws;selectively feeding one screw set of the plurality of screw sets into astandby position of a drop funnel; positioning a loading station thatincludes a tubular member below an outlet opening of the drop funnel;dropping the one screw set from the drop funnel and into the tubularmember; applying a shrink sleeve member around the tubular member;moving the tubular member to a first raised position to expose the onescrew set, such that the tubular member is no longer positioned betweenthe shrink sleeve member and the one screw set, wherein, in the firstraised position, the tubular member surrounds an upper end of the onescrew set; applying heat to the shrink sleeve member while the tubularmember is in the first raised position, causing the shrink sleeve memberto shrink into holding contact with the one screw set to form a wrappedscrew bunch; cooling the shrink sleeve member; moving the tubular memberto a second raised position that is higher than the first raisedposition, such that the wrapped screw bunch is no longer surrounded bythe tubular member and can be removed from the loading station.
 22. Themethod of claim 21, wherein the applying heat step is a primary heatingstep and the method further comprises applying further heat to theshrink sleeve member in a secondary heating step to cause the shrinksleeve member to further shrink.
 23. The method of claim 22 wherein thesecondary heating step occurs after the cooling step.
 24. The method ofclaim 23 wherein a secondary cooling step occurs after the secondaryheating step.
 25. The method of claim 21 wherein: in the separating stepeach screw set is moved into a respective channel of a carousel; the onescrew set is selectively fed to the standby position by rotating thecarousel such that an outfeed end of a channel holding the one screw setaligns with a carousel gate that leads to a feed track that runsdownward to the drop funnel such that the screws of the one screw setslide down along the feed track and into the standby position; theloading station is positioned below the outlet opening of the dropfunnel by rotating a station turntable; the one screw set is droppedfrom the drop funnel by linear movement of a gate member from a holdposition to a drop position, wherein, in the hold position, the gatemember supports the screws of the one screw set by engagement with theenlarged head ends of the screws and wherein, in the drop position, thegate member moves away from the enlarged head ends of the screws; thetubular member is moved to the first raised position by engaging thetubular member with a tube lifter, wherein the tube lifter has a lowerend, an upper end for engaging the tubular member and a radially innerend, wherein the lower end includes a lower roller that rides upwardalong a ramp surface as the station turntable rotates to a position forapplying heat, wherein the radially inner end includes an inner rollerthat rides within a cam slot as the station turntable rotates and thecam slot is configured such that tube lifter is disengaged from thetubular member when the shrink sleeve member is applied around thetubular member and such that the tube lifter moves into engagement withthe tubular member after the shrink sleeve member is applied around thetubular member and before the lower roller rides upward along the rampsurface; the heat is applied to the shrink sleeve member by rotating theloading station through a curved heat shrink tunnel; the cooling isperformed by blowing air onto the shrink sleeve member through one ormore openings in the station turntable that are located proximate to theloading station; and the tubular member is moved to the second raisedposition as the station turntable rotates causing the lower roller toride upward along a second ramp surface.
 26. A machine for producingwrapped screw bunches, comprising: a turntable including a plurality ofscrew load stations, the turntable rotatable about a first rotationaxis, each screw load station including an associated tubular member andan associated tube lifter; a carousel including a plurality ofdownwardly sloped screw channels for supporting groups of screws, thecarousel rotatable about a second rotation axis, the carousel surroundedby a stationary wall having an outlet gate that is selectively alignablewith an outfeed end of each screw channel based upon rotational positionof the carousel; a curved feed track running downwardly from the outletgate such that screws can slide downward along the feed track, the feedtrack having an outlet end; a drop funnel having a support track with aninlet end that is aligned with the outlet end of the feed track, thesupport track formed in part by a wall of the drop funnel and in part bya movable gate of the drop funnel, the drop funnel including a bottomopening; wherein each screw load station is rotatable along a path thatincludes a position below the bottom opening so that a group of screwscan be dropped into the tubular member of the load station to form aloaded tube.
 27. The machine of claim 26, further comprising: a shrinksleeve applicator located along the path, in a position that follows thedrop funnel, for applying a shrink sleeve member around the loaded tube,wherein the tube lifter is moved to a position away from the tubularmember during application of the shrink sleeve member.
 28. The machineof claim 27, further comprising: a shrink sleeve heater located alongthe path, in a position that follows the shrink sleeve applicator, forapplying heat to the shrink sleeve member, wherein, during shrink sleeveheating, the tube lifter is moved to a position engaging the tubularmember and lifting the tubular member to a raised position such that thescrews in the loaded tube are at least partially exposed and the tubularmember is no longer positioned between the shrink sleeve member and thescrews.
 29. The machine of claim 28, further comprising: a shrink sleevecooling station located along the path, in a position that follows theshrink sleeve heater, at which cooling air is blown onto the shrinksleeve member.
 30. The machine of claim 29, wherein the tube lifterincludes a lower end, an upper end for engaging the tubular member and aradially inner end, wherein the radially inner end includes an innerroller that rides within a cam slot as the turntable rotates, whereinthe cam slot is configured such that tube lifter is spaced away from thetubular member when the tubular member aligns with the shrink sleeveapplicator, wherein the cam slot is configured such that the tube liftermoves back toward and into engagement with the tubular member as thetubular member moves toward the shrink sleeve heater, wherein the lowerend includes a lower roller that rides upward along a ramp surface asthe turntable rotates to move the tubular member through the shrinksleeve heater.
 31. The machine of claim 27, wherein each loading stationincludes a screw support surface that is non-planar.
 32. The machine ofclaim 31, wherein each screw support surface is conical.